Removal and Replacement

Fuel tank

Special tools:
999 5972 FIXTURE 999 5972 Fixture
951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.

Preparatory work

Drain the fuel system. See: Fuel system pressure release Fuel System Pressure Release.
Drain the fuel tank. See: Fuel tank draining Service and Repair.

Removal

Removing middle muffler
Remove the middle muffler.

Removing the propeller shaft
Remove the rear propeller shaft acc. to Propeller shaft Propeller Shaft.

Note! When removing the propeller shaft, do not put strain on the catalytic converter. Suspend the propeller shaft in a suitable position.

Removing plastic casing, left and right side





Remove the following on both sides:
- the 3 nuts
- the screw
- plastic casing

Removing rear heat shield cover





Remove:
- the 3 plastic nuts
- the heat shield cover.

Removing the fuel tank




Loosen the screws for the tank straps, 4 pcs.
Remove the tank retaining straps. Lower the tank slightly.
Use a lift




Remove the hose clamp for the hose to the filler pipe.

Note! Carefully loosen the hose from the fuel filler pipe, there may be fuel left in the tank.





Remove:
- the hose with the quick-coupling (1) for the charcoal filter canister
- the hose with the quick-coupling (2)
- the hose with the quick-coupling (3) for the evacuation pipe.




Remove the fuel hose. Use 951 2666 Replaced by 9997298 951 2666 Wrench (Replaced by 9997298)




Remove the level sensor's connector and pull it from its bracket.
Carefully lower the tank and make sure that no cables or hoses are trapped.
Remove the fuel hose with the quick-coupling




Drain remaining fuel and remove the tank.

Transferring components
Remove the fuel pump, see: Service and Repair
Install the fuel pump acc. to: Service and Repair
Remove the level sensor on the left side acc. to Level sensor fuel tank left Level Sensor Fuel Tank Left.
Install the level sensor on the left side acc. to Level sensor fuel tank left Level Sensor Fuel Tank Left.

Installation

Note! For tightening torques, see Specifications. Tightening Torque

Note! To ensure that there is no exhaust leakage, see: Flanged joint, assembling Flanged Joint, Assembling

Installing the fuel tank




Place the tank on the mobile jack together with fixture: 999 5972 FIXTURE 999 5972 Fixture.
Raise the tank so that it is 30 cm from the top.

Install:
- the hose with the quick-coupling (3) for the evacuation pipe
- the hose with the quick-coupling (1) for the charcoal filter canister
- the hose with the quick-coupling (2)
- the fuel hose with the quick-coupling, 2 pcs.
- the connector for the level sensor.




Lift up the fuel tank.

Install:
- filler pipe with clamp
- the tank straps with screws, 4 pcs. M8

Installing rear heat shield cover





Install:
- the heat shield cover
- the 3 x plastic nuts.

Installing plastic casing on both left and right side





Install on both sides:
- plastic casing
- the 3 nuts
- the screw.

Installing the propeller shaft
Install the rear propeller shaft acc. to Propeller shaft Propeller Shaft

Installing middle muffler
Install the middle muffler.

Finishing

Top up the fuel.
Install the fuse for the fuel pump (FP).